Method of and apparatus for manufacturing tantalum solid electrolytic capacitors

Abstract

A length of metallic lead from having anode terminals and cathode terminals integrally formed with each other extends between upper and lower molds of an apparatus for manufacturing tantalum solid electrolytic capacitors. The cathode terminals are first coated with a thermosetting conductive adhesive, and cathode layers of capacitor elements are then placed on the conductive adhesive. Thereafter, anode leads extending outwardly from the capacitor elements are placed on the anode terminals are joined thereto, respectively, by welding. A pressure is applied to the capacitor elements so that a portion of the conductive adhesive is squeezed out from one surface of each of the plurality of capacitor elements to a neighboring side surface thereof. The cathode terminals are then joined to the capacitor elements, respectively, by heat-curing the conductive adhesive, and the capacitor elements are finally covered with a sheathing resin.

What is claimed is:  
     
       1. An apparatus for manufacturing solid tantalum electrolytic capacitors, comprising: a lower mold having an upper surface constructed and arranged to receive a length of a metallic frame having plural anode terminals and plural cathode terminals, wherein the plural anode terminals are to be joined to respective anode leads extending outwardly from plural capacitor elements, and the plural cathode terminals are coated with a thermosetting conductive adhesive onto which surfaces of the plural capacitor elements are placed; 
       an upper mold mounted on said lower mold and having a lower surface spaced from said upper surface of said lower mold; and  
       a heater mounted in said lower mold, such that when a pressure is applied to the plural capacitor elements, via said lower surface of said upper mold, by moving said upper mold towards said lower mold, a portion of the thermosetting conductive adhesive is squeezed from between the plural cathode terminals and the surfaces of the plural capacitor elements to respective adjacent side surfaces of the plural capacitor elements, whereby the thermosetting conductive adhesive remaining between the plural cathode terminals and the surfaces of the plural capacitor elements achieves a substantially uniform thickness, and  
       such that when said heater is activated the plural cathode terminals and the capacitor elements become joined together by heat-curing of the thermosetting conductive adhesive.  
     
     
       2. The apparatus according to  claim 1 , wherein said upper mold is slidably connected to said lower mold so as to move up and down relative to said lower mold. 
     
     
       3. The apparatus according to  claim 2 , further comprising a water-repellant and heat-resistant sheet attached to said upper surface of said lower mold. 
     
     
       4. The apparatus according to  claim 2 , further comprising a heat-resistant elastic material attached to said lower surface of said upper mold. 
     
     
       5. The apparatus according to  claim 2 , further comprising a heater mounted in said upper mold. 
     
     
       6. The apparatus according to  claim 2 , further comprising a thermal insulating panel disposed adjacent to said lower mold so as to confront a side surface thereof. 
     
     
       7. The apparatus according to  claim 2 , further comprising a load regulating mechanism for regulating a load to press said upper mold against the plural capacitor elements when the plural capacitor elements are supported by said upper surface of said lower mold. 
     
     
       8. The apparatus according to  claim 1 , wherein said upper mold is wingedly connected to said lower mold so as to be pivotable about a fulcrum relative to said lower mold. 
     
     
       9. The apparatus according to  claim 8 , further comprising a water-repellant and heatresistant sheet attached to said upper surface of said lower mold. 
     
     
       10. The apparatus according to  claim 8 , further comprising a heat-resistant elastic material attached to said lower surface of said upper mold. 
     
     
       11. The apparatus according to  claim 8 , further comprising a heater mounted in said upper mold. 
     
     
       12. The apparatus according to  claim 8 , further comprising a thermal insulating panel disposed adjacent to said lower mold so as to confront a side surface thereof. 
     
     
       13. The apparatus according to  claim 8 , further comprising a load regulating mechanism for regulating a load to press said upper mold against the plural capacitor elements when the plural capacitor elements are supported by said upper surface of said lower mold. 
     
     
       14. The apparatus according to  claim 1 , further comprising a water-repellant and heat-resistant sheet attached to said upper surface of said lower mold. 
     
     
       15. The apparatus according to  claim 1 , further comprising a heat-resistant elastic material attached to said lower surface of said upper mold. 
     
     
       16. The apparatus according to  claim 1 , further comprising a heater mounted in said upper mold. 
     
     
       17. The apparatus according to  claim 1 , further comprising a thermal insulating panel disposed adjacent to said lower mold so as to confront a side surface thereof. 
     
     
       18. The apparatus according to  claim 1 , further comprising a load regulating mechanism for regulating a load to press said upper mold against the plural capacitor elements when the plural capacitor elements are supported by said upper surface of said lower mold. 
     
     
       19. An apparatus for manufacturing solid tantalum electrolytic capacitors, comprising: 
       a lower mold having an upper surface constructed and arranged to receive a length of a metallic frame having plural anode terminals and plural cathode terminals, wherein the plural anode terminals are to be joined to respective anode leads extending outwardly from plural capacitor elements, and the plural cathode terminals are coated with a thermosetting conductive adhesive onto which surfaces of the plural capacitor elements are placed;  
       an upper mold mounted on said lower mold for up and down movement relative thereto, said upper mold having a lower surface spaced from said upper surface of said lower mold;  
       a water-repellant and heat-resistant sheet attached to said upper surface of said lower mold;  
       a heat-resistant elastic material attached to said lower surface of said upper mold;  
       a thermal insulating panel disposed adjacent to said lower mold so as to confront a side surface thereof;  
       a load regulating mechanism for regulating a load to press said upper mold against the plural capacitor elements when the plural capacitor elements are supported by said upper surface of said lower mold;  
       a heater mounted in said upper mold; and a heater mounted in said lower mold, such that when a pressure is applied to the plural capacitor elements, via said heat-resistant elastic material, by moving said upper mold towards said lower mold, a portion of the thermosetting conductive adhesive is squeezed from between the plural cathode terminals and the surfaces of the plural capacitor elements to respective adjacent said surfaces of the plural capacitor elements, whereby the thermosetting conductive adhesive remaining between the plural cathode terminals and the surfaces of the plural capacitor elements achieves a substantially uniform thickness, and  
       such that when said heaters are activated the plural cathode terminals and the capacitor elements become joined together by heat-curing of the thermosetting conductive adhesive.  
     
     
       20. An apparatus for manufacturing solid tantalum electrolytic capacitors, comprising: 
       a lower mold having an upper surface constructed and arranged to receive a length of a metallic frame having plural anode terminals and plural cathode terminals, wherein the plural anode terminal are to be joined to respective anode leads extending outwardly from plural capacitor elements, and the plural cathode terminals are coated with a thermosetting conductive adhesive onto which surfaces of the plural capacitor elements are placed;  
       an upper mold mounted on said lower mold for pivotal movement relative thereto, said upper mold having a lower surface spaced from said upper surface of said lower mold;  
       a water-repellant and heat-resistant sheet attached to said upper surface of said lower mold;  
       a heat-resistant elastic material attached to said lower surface of said upper mold;  
       a thermal insulating panel disposed adjacent to said lower mold so as to confront a side surface thereof,  
       a load regulating mechanism for regulating a load to press said upper mold against the plural capacitor elements when the plural capacitor elements are supported by said upper surface of said lower mold;  
       a heater mounted in said upper mold; and  
       a heater mounted in said lower mold,  
       such that when a pressure is applied to the plural capacitor elements, via said heat-resistant elastic material, by moving said upper mold towards said lower mold, a portion of the thermosetting conductive adhesive is squeezed from between the plural cathode terminals and the surfaces of the plural capacitor elements to respective adjacent side surfaces of the plural capacitor elements, whereby the thermosetting conductive adhesive remaining between the plural cathode terminals and the surfaces of the plural capacitor elements achieves a substantially uniform thickness, and  
       such that when said heaters are activated the plural cathode terminals and the capacitor elements become joined together by heat-curing of the thermosetting conductive adhesive.